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At least 1,261 records · Page 70

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NASA NTRS2015

Advancing the State-of-the-Practice for Liquid Rocket Engine Injector Design

Current shortcomings in both the overall injector design process and its underlying combustion stability assessment methodology are rooted in the use of empirically based or low fidelity representations of complex physical phenomena and geometry details that have first order effects on performance, thermal environments and combustion stability. The result is a design and analysis capability that is often inadequate to reliably arrive at a suitable injector design in an efficient manner. Specifically, combustion instability has been particularly difficult to predict and mitigate. Large hydrocarbon-fueled booster engines have been especially problematic in this regard. Where combustion instability has been a problem, costly and time-consuming redesign efforts have often been an unfortunate consequence. This paper presents an overview of a recently completed effort at NASA Marshall Space Flight Center to advance the state-of-the-practice for liquid rocket engine injector design. Multiple perturbations of a gas-centered swirl coaxial (GCSC) element that burned gaseous oxygen and RP-1 were designed, assessed for combustion stability, and tested. Three designs, one stable, one marginally unstable and one unstable, were used to demonstrate both an enhanced overall injector design process and an improved combustion stability assessment process. High-fidelity results from state-of-the-art computational fluid dynamics CFD simulations were used to substantially augment and improve the injector design methodology. The CFD results were used to inform and guide the overall injector design process. They were also used to upgrade selected empirical or low-dimensional quantities in the ROCket Combustor Interactive Design (ROCCID) stability assessment tool. Hot fire single element injector testing was used to verify both the overall injector designs and the stability assessments. Testing was conducted at the Air Force Research Laboratory and at Purdue University. Companion papers provide details of the overall injector design process, full- and sub-scale testing, ROCCID-based stability assessments and the CFD simulations.

Tucker, P. K.↗

NASA NTRS2017

Comparison of Aero-Propulsive Performance Predictions for Distributed Propulsion Configurations

NASA's X-57 "Maxwell" flight demonstrator incorporates distributed electric propulsion technologies in a design that will achieve a significant reduction in energy used in cruise flight. A substantial portion of these energy savings come from beneficial aerodynamic-propulsion interaction. Previous research has shown the benefits of particular instantiations of distributed propulsion, such as the use of wingtip-mounted cruise propellers and leading edge high-lift propellers. However, these benefits have not been reduced to a generalized design or analysis approach suitable for large-scale design exploration. This paper discusses the rapid, "design-order" toolchains developed to investigate the large, complex tradespace of candidate geometries for the X-57. Due to the lack of an appropriate, rigorous set of validation data, the results of these tools were compared to three different computational flow solvers for selected wing and propulsion geometries. The comparisons were conducted using a common input geometry, but otherwise different input grids and, when appropriate, different flow assumptions to bound the comparisons. The results of these studies showed that the X-57 distributed propulsion wing should be able to meet the as-designed performance in cruise flight, while also meeting or exceeding targets for high-lift generation in low-speed flight.

Borer, Nicholas K.↗

NASA NTRSDate not supplied

GlennICE 2.2 Capabilities and Results

GlennICE (Glenn Icing Computational Environment) is a computational tool designed to calculate ice growth on complex three-dimensional geometries using the input from a user-supplied computational fluid dynamics (CFD) solution for the geometry of interest. The NASA John H. Glenn Research Center at Lewis Field is developing this tool to aid those evaluating, designing and certifying aircraft, engines, and aircraft components for flight in icing conditions. This domestically available software is being developed to enable the introduction of new icing physics into a computational environment in a manner that is open for evaluation and eventual use by industry, academia, and other government organizations. This paper will document the current capabilities for version 2.1 of this software and provide example cases with comparison to available experimental data.

Icing↗

NASA NTRSDate not supplied

GlennICE 2.2 Capabilities and Results

Icing↗

NASA NTRS2022

Multiscale Progressive Failure Analysis of 3D Woven Composites

Application of three-dimensional (3D) woven composites is growing as an alternative to the use of ply-based composite materials. However, the design, analysis, modeling, and optimization of these materials is more challenging due to their complex and inherently multiscale geometries. Herein, a multiscale modeling procedure, based on efficient, semi-analytical micromechanical theories rather than the traditional finite element approach, is presented and applied to a 3D woven carbon–epoxy composite. A crack-band progressive damage model was employed for the matrix constituent to capture the globally observed nonlinear response. Realistic microstructural dimensions and tow-fiber volume fractions were determined from detailed X-ray computed tomography (CT) and scanning electron microscopy data. Pre-existing binder-tow disbonds and weft-tow waviness, observed in X-ray CT scans of the composite, were also included in the model. The results were compared with experimental data for the in-plane tensile and shear behavior of the composite. The tensile predictions exhibited good correlations with the test data. While the model was able to capture the less brittle nature of the in-plane shear response, quantitative measures were underpredicted to some degree.

3D woven composites↗

NASA NTRSDate not supplied

Scalability of GlennICE in a Parallel Environment

The Glenn Icing Computational Environment (GlennICE) is a computational tool designed to calculate ice growth on complex three-dimensional geometries using the input from a user-supplied computational fluid dynamics (CFD) solution for the geometry of interest. The most significant developments in the advancement of GlennICE have been investigating the convergence of the collection efficiency, efficiently finding trajectories, and improving the refinement methodology. Such developments have increased the efficiency of GlennICE for practical engineering application. With the increasing demand for applying GlennICE for more memory-intensive problems, the scalability of GlennICE has yet to be investigated. This paper is aimed at presenting a method to benchmark the scalability of GlennICE utilizing a relevant engineering problem within a parallel environment. This leads to the final goal of investigating whether an increase in the number of processors utilized results in a linear speedup of the GlennICE software.

Computational Icing, Icing, CFD, MPI↗

NASA NTRSDate not supplied

Modeling of Particle Transport and Impact in Transient, Multiphase Oxidizer-Rich Environments Using Computational Fluid Dynamics and Lagrangian Particle Tracking

Particle impacts from foreign object debris (FOD) in an oxidizer-rich environment have been shown to be a credible and significant risk for ignition and failure of components and vehicles. The risk of particle ignition is dependent on many factors, including particle impact velocity/energy and fluid composition (i.e. fluid phase, species presence, and state). Prediction of particle transport and particle impacts in relevant environments, including transient, multiphase flows, is important for assessing the risk and avoiding repeated expensive system level tests. The capability to model both the fluid dynamics and particle transport in complex three-dimensional geometries and multiphase environments has been developed at Marshall Space Flight Center (MSFC) in the propulsion fluid dynamic branch (ER42) by utilizing computational fluid dynamics (CFD) simulations and Lagrangian particle tracking. Using CFD tools, including density-based Loci/CHEM with a cavitation model and pressure-based Loci/STREAM with a volume of fluids model, MSFC/ER42 has provided particle impact predictions to multiple projects for oxidizer compatibility assessments. Simulations of transient, multiphase environments such as liquid slugs flowing through tubing and cavitating flow in valves have been completed alongside one-way coupled Lagrangian particle tracking to predict particle impacts.

M.V. Fischels↗

NASA NTRS2024

GlennICE Manual 4.1.0

Icing↗

NASA NTRSDate not supplied

A Study of Parallel Scalability and Dynamic Workload Balancing in GlennICE

The Glenn Icing Computational Environment (GlennICE) is a computational tool designed to calculate ice growth on complex three-dimensional geometries. It utilizes user-supplied computational fluid dynamics solutions for the geometry of interest. Key developments include advancements in convergence of collection efficiency, trajectory optimization, and refinement methodology. These improvements have significantly enhanced GlennICE’s efficiency for practical engineering applications. A recent study focused on benchmarking GlennICE’s scalability in a parallel environment using static scheduling. Findings indicated a potential twofold increase in efficiency through workload balance enhancements. This paper presents an analysis of the solver’s new workload balancing improvements, incorporating shared memory and dynamic scheduling routines. Results demonstrate a highly efficient and consistent algorithm across high-performance computing clusters.

Computational Icing↗

NASA NTRS2024

Experimental and Computational Study of Convective Heating on the Aeroshell Back Side and Payload of the LOFTID Vehicle

A wind tunnel test program was conducted to obtain experimental convective heating data on models of the Low Earth Orbital Flight Test of an Inflatable Decelerator (LOFTID) vehicle in support of the flight test program. Wind tunnel testing was conducted at Mach 6 and Mach 10 at unit Reynolds numbers from 0.5×106/ft to 4.0×106/ft on 6.0inch diameter aeroshell models. Global heating data were obtained through phosphor thermography measurements on the front and back of the aeroshell and on the payload. For all test conditions, attached, laminar flow was definitively produced on the front of the aeroshell, while in the wake the flow was separated, unsteady and possibly transitional or turbulent. A complementary computational study was performed to assess the accuracy of heating predictions for LOFTID wake flow environments. A new grid topology was developed for the study to allow the use of structured grid solvers for complex, open-backed geometries such as that of LOFTID. Close agreement between measurements and predictions was obtained on the front of the aeroshell. Comparisons were more challenging in the wake because of both the extremely low heating rates and the accompanying high uncertainties and the unsteady nature of the separated wake flow simulations. While the differences between heating predictions and measurements for the wake flow were higher than for the forebody flow, these differences were used to assist in the definition of conservative uncertainty margins for predictions of the flight environments for the successful flight test of the LOFTID vehicle in November 2022.

LOFTID↗

NASA NTRSDate not supplied

Sources of Uncertainty in Ultrasonic Phase-Based Assessment of Interfacial Stiffness in Adhesive Joints

Quantitative nondestructive evaluation (NDE) of adhesive joint strength is critical for certifying fastener-free bonded aerospace structures. Unfortunately, available adhesive NDE approaches are only suitable for detecting gross defects and delamination and cannot reliably detect variations in strength in intact bonds. Intact (i.e., nominally defect free) bonds are challenging to inspect because they, by definition, contain no macroscopic defects that would produce a strong NDE signature. Even in the absence of obvious defects, however, bond strength can vary substantially due to factors such as contamination, variations in the adhesive cure processes, and environmental exposure. For ultrasonic bond inspections, the effect of interactions from an imperfect adhesive interface are subtle and may include changes in the frequency content or phase of the ultrasonic signal. The bond condition can be deduced from these subtle changes in the acoustic response using an accompanying physics-based model of adhesive joint interaction. For example, researchers have used the spring network adhesion model of Baik and Thompson [1] to determine the interfacial stiffness of the joint from its ultrasonic response (e.g., [2]). This interfacial stiffness metric describes the bonds resistance to separation between the adhesive and adherent and has shown a strong correlation with joint strength. In this study, interfacial stiffness is assessed using the ultrasonic phase change associated with bond interaction in varying bond conditions. The phase change is measured precisely using a phase-locked-loop instrument over a swept range of frequencies. The phase transition at resonance, where the bond thickness is half the acoustic wavelength, produces a unique signature with which to fit a physics-based model. Interfacial stiffness is determined by minimizing the difference between the theoretical and experimental phase response. Experimental results are presented for glass specimens bonded with aerospace adhesives and a sensitivity analysis is performed to examine the effects of parameters that may be uncertain in the industrial inspection environment – namely bond thickness, adhesive and adherent properties, and porosity. The results are a first step toward an uncertainty quantified version of the measurement technique, show correlation between interfacial stiffness and bond strength, and are another key step toward maturing this approach for use in complex materials and joint geometries. [1] Baik, J.M. and Thompson, R.B., 1984. “Ultrasonic scattering from imperfect interfaces: a quasi-static model”. Journal of Nondestructive Evaluation, 4. [2] Haldren, H.A., Perey, D.F., Yost, W.T., Cramer, K.E., and Gupta, M.C., 2019. “Swept-frequency ultrasonic phase evaluation of adhesive bonding in tri-layer structures”. Journal of the Acoustical Society of America, 145.

Matt Webster↗

NASA NTRSDate not supplied

A Study of Parallel Scalability and Dynamic Workload Balancing in GlennICE

Computational Icing↗

NASA NTRS2026

Influence of Processing Parameters on the Mechanical Properties of 3D Printed Borosilicate Particulate Reinforced Polymer Composites

Emerging composite materials are expanding the potential of additive manufacturing and enabling applications previously restricted by traditional manufacturing methods. The multi-phase nature of these composite materials combined with the complex in-ternal geometry of additively manufactured parts have enabled unique behavior, and potentially new applications. Additionally, these materials can be pyrolyzed to create dense metal, ceramic, and glass parts with geometries typically not achievable by tra-ditional processes. Additive manufacturing of borosilicate glass-based systems can open new applications in nuclear engineering, astronomy, and bone regrowth therapy. To elucidate the process-parameter relationship of borosilicate-polylactic acid (PLA) composites, mechanical testing was conducted and compared with a pure polylactic acid polymer baseline. Test specimens were fabricated by fused-filament fabrication with minimal post-processing. Yield strength, ultimate strength, and elastic modulus were calculated from stress-strain curves. Optical and scanning electron microscopy were conducted to observe the specimen microstructure before and after testing. The highest compressive yield strength for the composite was 28.22 MPa, and the highest compressive yield strength for PLA was 49.30 MPa. Print orientation was found to benefit the composite material but have a detrimental effect on the pure matrix material. An elastic modulus of 2.66 GPa was recorded for the borosilicate-PLA composite at 100% infill, 1 shell wall, and layer lines parallel to compression axis. Microscopy revealed that lower modulus composite specimens had the particulates re-distributed within the matrix. Tensile testing was done according to a polymer testing standard, which caused difficulties obtaining consistent fracture within the gauge length.

mechanical testing↗

DOE OSTI2024

Additive Manufacturing of Thermal Energy Storage Composites with Microencapsulated Phase Change Materials Supported in a Multi-Polymer Matrix

Advanced manufacturing techniques, such as additive manufacturing (AM), that can directly integrate phase change materials (PCMs) have garnered interest in recent years due to their potential for development of highly efficient thermal energy storage architectures. Complex, high surface area geometries embedded with PCMs that are only feasible with AM can improve thermal management with reduced material waste. Our work focuses on developing composite filaments with microencapsulated phase change materials (MEPCM) bound within a single or dual polymer matrix that can be processed through standard filament extruders and additively manufactured using off-the-shelf 3D printers. Polymer powders, rather than polymer pellets, were key to homogenously mixed filaments achieving high MEPCM loadings with no deterioration in thermal energy storage (TES) capability during extrusion. Composite filaments contain upwards of 60 wt% MEPCM and were printed without loss in feature resolution, print speed, or layer adhesion. Storage enthalpies of printed composites range from 100 - 130 kJ/kg, which were within 5% of the theoretical enthalpy based on weight fraction of MEPCM and maintained enthalpies within 1% over 500 thermal cycles. We can reliably manufacture low density, high surface area structures like 15% gyroid infill, along with dense, compact pucks at a 100% concentric infill. Prints were also scalable to a 900 cm3 honeycomb infill heat exchanger model that has an estimated energy storage capacity of 9 Wh.

3D printing↗

DOE OSTI2020

Overcoming geometric limitations in metallic glasses through stretch blow molding

Bulk metallic glasses (BMGs) exhibit remarkable mechanical properties, such as high strength and elasticity, which is often paired with fracture toughness. Their supercooled liquid region gives rise to plastic-like processing and suggests parts and shapes that can otherwise not be obtained for crystalline metals. However, current processing techniques only allow for limited options in terms of geometry, thicknesses uniformity, and shape complexity. Here we introduce a new processing technique, “stretch blow molding,” to expand the range of possible parts and increase the available geometries that can be fabricated with BMGs. Additionally, a model is derived that allows for the quantification and prediction of stretch blow molding and provides insight into its potential use and limitations. We demonstrate that with stretch blow molding overall strains exceeding 2000% are achievable, compared to the previously reported ~150% of blow molding. With the ability to stretch blow mold shapes that were previously unachievable with any other metal fabrication technique in a fast and economical manner, and the superb properties of BMGs, we look forward to a broad commercial adaptation of this technique.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Geometry-independent microstructure optimization for electron beam powder bed fusion additive manufacturing

The ability to manipulate the formation of microstructure is one of the potential advantages of additive manufacturing. Yet, the additive manufacturing process is riddled with complex interactions between processing parameters, geometry, and spot melting sequence which makes the task of controlling microstructure challenging. This paper proposes a method to solve the microstructure texture optimization problem by leveraging established optimization techniques and increasingly fast and accurate analytical heat transfer models. Respectively, we apply two different optimization algorithms, genetic algorithm and concurrent greedy line search, in order to induce arbitrarily shaped microstructure regions and we use a heat transfer model to evaluate the fitness of solutions in an iterative approach that is far more efficient than pure trial and error. The objective of the optimization algorithm is to control local thermal conditions – hence microstructure formation – during the melting process by manipulating the order and the dwell time of all the points of the infill pattern sequence. We then analyze the optimized sequence to determine important path characteristics that affect the microstructure formation. Through examples, we show that relative order and frequency, as measured by weighted average and variance of spot order, are important factors that influence the final characteristics.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Controlling Molecular Structure and Spin with Multiconfigurational Quantum Chemistry (Final Technical Report)

For many first-row transition metal complexes, structure-property relationships can be obtained from high-level molecular geometry optimizations and subsequent electronic structure studies. The project funded under this award utilized newly implemented fully internally contracted (FIC) nuclear gradients for extended multi-state (XMS) complete active space second-order multireference perturbation theory (CASPT2) to explore geometry changes in first-row transition metal coordination complexes. At the start of the project, only one full geometry optimization using FIC-CASPT2 analytical gradients had been reported (J. Chem. Theory Comput., 2016, 12 (8), 3781), and many open-questions regarding the performance and achievable accuracy in applying such computations to larger complexes persisted. Key deliverables in the report include the implementation of the numerical Hessian and subsequent vibrational analysis in the BAGEL program package. This includes both full Hessian vibrational analysis (FHVA) and a partial Hessian vibrational analysis (PHVA). The latter of which allows us to reduce the significant cost of computing the vibrational frequencies in a large molecule by focusing on the modes of highest interest. The gradient code also proved useful in the development of an approach to improve the Hubbard-U correction by removing bias in predicting spin-splitting in Fe(II) complexes via plane-wave density functional theory (DFT). Finally, we showed for three families of complexes (spin-crossover (SCO) complexes, metallocorroles complexes, and those with metal-metal bonds) that CASPT2 can result in good molecular geometries and established best practices in undertaking this work. We are now using this approach in collaborative projects with experimental groups, which would not have been possible at the start of this project. A common theme also arose through this work that static and dynamic correlation must be recovered in a balanced way to yield quantitative results. By systematically varying how both effects were included, we were able to make key chemical insights. This work supported the training of two postdoctoral scholars, one graduate student, and one undergraduate student in applying high-level wavefunction based methods to challenging systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1989

Computational solution of chemistry problems

AB initio quantum chemical techniques have been used to investigate weakly bound complexes of H2O and SO2. An energy gradient program was used to locate stable structures for the H2O, SO2 complexes, and SCF calculations were carried out to determine the binding energies of complexes with multiple water molecules. A 4-31G basis set was used for most potential energy searches. More accurate basis sets including a generally contracted basis set with d orbitals on the sulfur were used for geometry and binding energy verification. For single water complexes, five different stable geometries were located with binding energies between 4 and 11 Kcal mol(-1), suggesting a binding shell for H2O around SO2 and a mechanism for the formation of an SO2-containing water droplet. Calculations on one of the complexes utilizing a larger double zeta basis and d functions on the sulfur atom lead to adjusted binding energies in the range 3 to 8 Kcal mol(-1). Very little charge transfer between SO2 and H2O was present. Addition of more than one H2O was found to be energetically favorable although the addition of the fourth water in certain geometries did not increase the stability of the complex. An alternative mechanism for the tropospheric gas phase production of acid rain is suggested.

Ake, Robert L.↗